Co-continuous interconnecting channel morphology composition

ABSTRACT

The present invention includes a composition having a co-continuous interconnecting channel morphology. These co-continuous interconnecting channels are predominately occupied with a polymer and particles that control the percolation through the composition. The particles are composed of a material such as an absorbing agent, releasing agent and/or activation agent. The polymer composition may be used to form a desired shaped article such as plug type inserts and liners for closed containers, or it may be formed into a film, sheet, bead or pellet.

RELATED APPLICATION

[0001] This application is a divisional of U.S. Ser. No. 09/504,029,filed Feb. 14, 2000, which is a continuation-in-part of U.S. Ser. Nos.09/156,937, 09/157,032, 09/157,014, and 09/156,720, filed Sep. 18, 1998,which in turn is a continuation-in-part of U.S. Ser. No. 09/087,830,filed May 29, 1998, U.S. Pat. No. 6,124,006 which in turn is acontinuation-in-part of U.S. Ser. No. 08/812,315, U.S. Pat. No.6,130,263 filed March 5, 1997, which inturn is a continuation-in-part ofU.S. Ser. No.08/611,298, U.S. Pat. No. 5,911,937 filed on March 5, 1996.

FIELD OF THE INVENTION

[0002] This invention generally relates to a composition havingco-continuous interconnecting channel morphology comprising threecomponents—two polymers (i.e. components A and B) and a particle (i.e.component C) wherein the channels consist mainly of component B and themajority of component C resides in the channels. Components A and B aregenerally immiscible within each other. In addition, one criteria forselecting component C and components A and B may be based on component Cpreferential affinity for component B over component A. Another criteriafor selecting component C may be based on the capacity of component C toabsorb and/or release a desired substance. For example, component C maybe an absorbing material such as desiccant. In one embodiment, thecomposition of the present invention is useful in the manufacture ofshaped articles such as containers and packaging for items requiringcontrolled environments.

BACKGROUND OF THE INVENTION

[0003] There are many items that are preferably stored, shipped and/orutilized in an environment that must be controlled and/or regulated. Forexample, in the moisture control area, containers and/or packages havingthe ability to absorb excess moisture trapped therein have beenrecognized as desirable. One application in which moisture absorbingcontainers are desired is for the shipment and storage of medicationswhose efficacy is compromised by moisture. The initial placement ofmedicines into a sealed moisture free container is usually controllable.Furthermore, the container for the medicine is selected so that is has alow permeability to moisture. Therefore, the medication will normally beprotected from moisture until it reaches the end user. Once the medicineis received by the customer, however, the container must be repeatedlyopened and closed to access the medication. Each time the container isopened and unsealed, moisture bearing air will most likely be introducedinto the container and sealed therein upon closure. Unless this moistureis otherwise removed from the atmosphere or head space of the container,it may be detrimentally absorbed by the medication. For this reason, itis a well known practice to include a desiccating unit together with themedication in the container.

[0004] Other items, electronic components may require reduced moistureconditions for optimal performance. These components may be sealed incontainers, but excess moisture that is initially trapped therein mustbe removed. Furthermore, the housings may not be completely moisturetight, and moisture may be allowed to seep into the container. Thismoisture must also be retained away from the working components. Forthese reasons, it is important to include a desiccating agent within thehousing for absorbing and retaining excess moisture. Because of thedelicacy of many of the components that are to be protected from themoisture, it is important that the desiccant used not be of a “dusting”nature that may contaminate and compromise the performance of thecomponents. Therefore, it has been recognized as advantageous to exposea desiccating agent to the interior space of such containers, while atthe same time shielding the working components from actual contact withthe desiccating material, including desiccant dust that may be producedtherefrom.

[0005] In other instances, moisture may be released from items that havebeen placed in containers or sealed in packaging wrap for shippingand/or storage. Prime examples of such items are food stuffs-thatrelease moisture during shipping and storage. In the instance ofcontainers that are sealed and substantially impermeable to moisture,the released moisture will remain within the container. If not removed,this released moisture may have ill effects on the very item thatreleased the moisture. It has been found that a substantial amount ofmoisture is released from certain food products within the firstforty-eight (48) hours after manufacture and packaging. This releasedmoisture will remain until removed. If the moisture is not removedshortly after its release, it may cause the food to degrade into acondition that is not saleable. In these cases, desiccants may beincluded together with the contained items to continually absorb thereleased moisture until the product is unpacked. In this way, arelatively dry environment is maintained about the stored item.

SUMMARY OF THE INVENTION

[0006] The present invention discloses a composition havingco-continuous interconnecting channel morphology. In one embodiment,these co-continuous interconnecting channels communicate the particle,which is predominately residing in the channels, to the appropriateareas of the exterior of the composition in a manner that permits thedesired property (e.g., gases and vapors) to migrate from either outsidethe composition to interior locations where the particle is positionedor from the interior locations where the particle is positioned to theenvironment. Furthermore, these co-continuous interconnecting channelsthrough which the desired property is permitted to travel are occupiedby a polymer (e.g., hydrophilic agents) that control the percolationthrough the composition. This polymer is drawn out into interconnectedchannels that contain a percolation path.

BRIEF DESCRIPTION OF DRAWINGS

[0007]FIG. 1 is a perspective view of a plug, insert, or tabletconstructed from the composition of the present invention showing, in anexaggerated scale, the openings of the co-continuous interconnectingchannels morphology at the exterior surface of the plug.

[0008]FIG. 2 is an exaggerated, cross-sectional view of a solidifiedplug formed from a water-insoluble polymer having a hydrophilic agentand an absorbing material blended therewith.

[0009]FIG. 3 is an exaggerated cross-sectional view of a portion of acontainer having the composition of the present invention formed into aplug insert located in the bottom of a container constructed from apolymer that acts as a transmission rate barrier.

[0010]FIG. 4 is an exaggerated cross-sectional view of a portion of acontainer the composition of the present invention formed into a plugthat has been comolded into the bottom of a container that isconstructed from a polymer that acts as a transmission rate barrier.

[0011]FIG. 5 is an exaggerated cross-sectional view of a portion of acontainer the composition of the present invention formed into a linerinsert located within the interior of a container constructed from apolymer that acts as a transmission rate barrier.

[0012]FIG. 6 is an exaggerated cross-sectional view of a portion of acontainer having the composition of the present invention formed into aliner that has been comolded at the interior of a container that isconstructed from a polymer that acts as a transmission rate barrier.

[0013]FIG. 7 is an exaggerated cross-sectional view of the compositionof the present invention formed into a sheet located adjacent to abarrier sheet constructed from a polymer that acts as a transmissionrate barrier.

[0014]FIG. 8 is an exaggerated cross-sectional view the composition ofthe present invention formed into a sheet that has been comolded at aninterior of a barrier sheet so that the products are integrally moldedtogether and comprise one unified laminate.

[0015]FIG. 9 is a graphical view of a swelling and weight loss analysisof three film samples: Film #2, Film #3 and Film #4.

[0016]FIG. 10 is a graphical view of a DSC curve of a sample of 100%polyglycol.

[0017]FIG. 11 is a graphical view of a DSC curve of a sample of Film #4.

[0018]FIG. 12 is a graphical view of a DSC curve of a sample of Film #5.

[0019]FIG. 13 is a graphical view of an DSC curve of a sample of Film#6.

[0020]FIG. 14 is a graphical view of a DSC curve of a sample of Film #7.

[0021]FIG. 15 is a graphical view of a DSC curve of a sample of Film #2in a pre-incubation state.

[0022]FIG. 16 is a graphical view of a DSC curve of a sample of Film #2in a post-incubation state.

[0023]FIG. 17 is a graphical view of a DSC curve of a sample of Film #3in a pre-incubation state.

[0024]FIG. 18 is a graphical view of a DSC curve of a sample of Film #3in a post-incubation state.

[0025]FIG. 19a-c are scanning electron photomicrographs of a film sampleof Film #4.

[0026]FIG. 20a-c are scanning electron photomicrographs of a film sampleof Film #5.

[0027]FIG. 21a-c are scanning electron photomicrographs of a film sampleof Film #6.

[0028]FIG. 22a-d are scanning electron photomicrographs of a film sampleof Film #3.

[0029]FIGS. 23a and 23 b is a graphical view of showing the percentmoisture gain per weight of molecular sieve at 10% Rh and 72 F. and 20%RH and 72 F., respectively.

[0030] Among those benefits and improvements that have been disclosed,other objects and advantages of this invention will become apparent fromthe following description taken in conjunction with the accompanyingdrawings. The drawings constitute a part of this specification andinclude exemplary embodiments of the present invention and illustratevarious objects and features thereof.

DETAILED DESCRIPTION OF THE INVENTION

[0031] As required, detailed embodiments of the present invention aredisclosed herein; however, it is to be understood that the disclosedembodiments are merely exemplary of the invention that may be embodiedin various forms. The figures are not necessarily to scale, somefeatures may be exaggerated to show details of particular components.Therefore, specific structural and functional details disclosed hereinare not to be interpreted as limiting, but merely as a basis for theclaims and as a representative basis for teaching one skilled in the artto variously employ the present invention.

[0032] It has been discovered that a composition having co-continuousinterconnecting channel morphology may be produced and that such acomposition may be used in the formation of shaped articles such ascontainers, sheets, films, pellets, beads and discs. Specifically, acomposition having co-continuous interconnecting channel morphology maybe formed comprising at least three components, wherein: (a) component Ais selected from the group of polymers that are semicrystalline polymersand amorphous polymers, wherein the amorphous polymers have a shearmodulus greater than about 8 MPa; (b) component B is a polymer; (c)components A and B are immiscible within each other, and if components Aand B react after mixing, components A and B are immiscible prior toreacting; (d) component C is a particle; (e) the volume fraction ofcomponent A represents at least about 50% by volume of the total volumeof components A, B and C; (f) the preferential affinity betweencomponent B and component C is greater than between component A andcomponent C; (g) at least two phases are formed, one phase is composedof a majority of component A, and the second phase is composed of amajority of components B and a majority of component C; and (h) twophases form the co-continuous interconnecting channel morphology.

[0033] Components A, B and C may be selected based on the desiredend-use result—the desired end-use property. For example, component Amay typically be selected based on its permeability properties (e.g.barrier properties), its chemical and/or temperature resistanceproperties, its molding properties, and/or its price (e.g. since it isthe component having the largest volume fraction of the composition).Similarly, for example, component B may typically be selected based onits transport properties (e.g. desired vapor or gas) and/or itspreferential affinity with component C. Also, for example, component Cmay typically be selected based on its ability to absorb, release and/oractivate the desired end-use material (e.g. vapor or gas). Consequently,a specific composition may be uniquely tailored and thus, uniquelyoptimized for a desired end-use application.

[0034] In one embodiment, component B may be a hydrophilic agent. In afurther embodiment, component C (i.e., the particle) may be an absorbingmaterial. In another embodiment, component C may be a releasingmaterial. In a further embodiment, component C may be an activationmaterial. In yet another embodiment, component C may be both anabsorbing and a releasing material.

[0035] For example, one method of forming the composition of the presentinvention is by adding component C and component B to component A, whichin one example is a water-insoluble polymer, when component A is in amolten state; or before component A is in the molten state, so thatcomponents B and C may be blended and thoroughly mixed throughoutcomponent A to insure that the blend is uniformly mixed before reachingthe melt phase. For example, such a technique may be useful whencomponents A, B and C are all powders. In another embodiment, componentB (such as a hydrophilic agent) and component A are mixed prior toadding component C. Component B is either added before component A is inthe molten state or after component A is in the molten state. Forexample, component C may be added to component A during the thermalprocess of forming sheets. After blending and processing, component B isdrawn out into interconnecting channels that contain a percolation pathin component A. The majority of component C resides in theinterconnecting channels because of its preferential affinity towardscomponent B over component A. In addition, the composition of thepresent invention may be described as “monolithic” because thecomposition does not consist of two or more discrete macroscopic layers.

[0036] For purposes of the present invention, the term “phase” means aportion of a physical system that is uniform throughout, has definedboundaries and, in principle, can be separated physically from otherphases. The term “water-insoluble polymer” means a polymer having asolubility in water below about 0.1% at 25° C. and atmospheric pressure.The term “hydrophilic agent” is defined as a material that is notcross-linked and that has a solubility in water of at least about 1% at25° C. and atmospheric pressure. Suitable hydrophilic agents include“channeling” agents. The term “melting point” is defined as the firstorder transition point of the material determined by DSC. The term “notmutually soluble” means immiscible with each other. The term“immiscibility” means that the components of the blend are driven bythermodynamic forces to separate (i.e. demix) into two or more distinctphases that will coexist indefinitely under equilibrium conditions. Anexample is the separation of the oil-rich and water-rich phases in asalad dressing. For purposes of the present invention, “partial”immiscibility or “partial” miscibility is deemed “immiscible” and thus,any tendency for a component to phase separate from another component isdeemed “immiscible.” Immiscibility may be determined by the applicationof one or more forms of microscopy (e.g., optical, TEM, SEM or AFM) withan observation that the components are separated into two or moredistinct phases. The term “particle” means a dispersed component that iseither a crystalline or amorphous solid, or a crosslinked organic orinorganic material, and that retains its shape, aside from recoverabledeformations, before, during, and after the blend is compounded in themolten state at elevated temperatures. This would include, e.g., acrosslinked polymer latex.

[0037] Further, for purposes of the present invention, the term“co-continuous interconnecting channel morphology” means that the minorphase (i.e., component B) is drawn out into interconnected channels thatcontain a percolation path, while simultaneously, the majority phase(i.e., component A) is percolating. “Percolation” means that thereexists at least one unbroken path, composed only of points from withinthat phase, that will lead from any surface of a sample through theinterior of the sample to any other surface. Such a percolation pathprovides a route for a desired object, such as a small molecule, anatom, an ion, or an electron, to be macroscopically transported acrossthe sample while contacting only one of the phases. For some systems,the existence of an interconnecting channel morphology that isco-continuous may be determined by a minimum of two transportmeasurements that demonstrate percolation in both minor and majorphases. Percolation theory is a mature branch of mathematics andphysical science that is described in a variety of review articles,specialized monographs, and many introductory texts on stochasticprocesses, probability theory, and statistical mechanics. For example,an introductory treatment of percolation theory is described by D.Stauffer in Introduction to Percolation Theory, Taylor and Francis,(London 1985).

[0038] The term “preferential affinity” means that the particle (i.e.,component C) has a lower interfacial energy when contacting onecomponent than compared to contacting another component. A suitablemethod for determining “preferential affinity” for the present inventionis the following:

[0039] (a) Blend the particle with the two components at elevatedtemperatures in their liquid state. Mix to achieve a macroscopicallyhomogeneous dispersion.

[0040] (b) Cool the mixture and allow to solidify.

[0041] (c) Use a form of microscopy (e.g., TEM, SEM, and/or AFM) on athin section to determine which of the two phases most closely contactseach particle in the field of view.

[0042] (d) The component that is in the majority in the phase thatcontacts the largest number of particles is the component with“preferential affinity” for the particle.

[0043] Further, the term “shear modulus” is the ratio of a measuredshear stress to the magnitude of a small, elastically recoverable, shearstrain that is used to produce that stress. The criterion of greaterthan about 8 MPa refers to the shear modulus measured at roomtemperature. The “shear modulus” is determined by ASTM test methodE143-87 (1998). The term “polymer” means a composition that is made byreacting two or more molecular species (“monomers”) to formchemically-bonded larger molecules. The term “semicrystalline” meansthat the polymeric component, at ambient temperature, contains regionsin which chain segments are packed with spatial registry into a periodiclattice and these regions are of sufficient size and extent to exhibit adetectable melting endotherm in a differential scanning calorimetry(DSC) measurement. The term “amorphous” means that the polymericcomponent, at ambient temperature, either contains no regions ofperiodic packing of segments, or such regions are undetectable with aDSC measurement.

[0044] In one embodiment, component B may be a hydrophilic agent.Suitable hydrophilic agents of the present invention may includepolyglycols such as poly(ethylene glycol) and poly(propylene glycol) andmixtures thereof. Other suitable materials may include EVOH,pentaerithritol, PVOH, polyvinylpyrollidine, vinylpyrollidone orpoly(N-methyl pyrollidone), and saccharide based compounds such asglucose, fructose, and their alcohols, mannitol, dextrin, and hydrolizedstarch being suitable for the purposes of the present invention sincethey are hydrophilic compounds.

[0045] In another embodiment, suitable hydrophilic agents of the presentinvention may also include any hydrophilic material wherein, duringprocessing, the hydrophilic agent is heated above its melt point uponmelt mixing, and subsequently upon cooling separates from the polymer toform the interconnecting channeled structure of the present inventionand a three phase system of a water-insoluble polymer, hydrophilic agentand an absorbing material.

[0046] In one embodiment, the particle (i.e., component C) may becomposed of one or more type of absorbing materials. For example,absorbing material of the present invention may include one or moredesiccating compounds. In general, there are three primary types ofdesiccating compounds that may be used with the present invention. Thefirst type comprises chemical compounds that can combine with water toform hydrates. Examples of such desiccant are anhydrous salts which tendto absorb water or moisture and form a stable hydrate. In this reactionwith the moisture, a stable compound is formed within which the moistureis held and prevented from release by chemical interaction.

[0047] The second type of desiccant compounds are those which areconsidered to be reactive. These compounds typically undergo a chemicalreaction with water or moisture and form new compounds within which thewater is combined. These newly formed compounds are generallyirreversible at low temperature and require a significant amount ofenergy to be regenerated so that they may be reused as a desiccant.These reactive type desiccants are mainly used in solvent drying and aswater-absorbing materials to polymers which must themselves bemaintained in a moisture reduced state

[0048] The third type of desiccants obtain their moisture absorbingcapabilities through physical absorption. The absorption process isaccomplished because of a fine capillary morphology of the desiccantparticles which pulls moisture therethrough. The pore size of thecapillaries, as well as the capillaries' density determine theabsorption properties of the desiccant. Examples of these physicalabsorption desiccants include molecular sieves, silica gels, clays (e.g.montmorillimite clay), certain synthetic polymers (e.g. those used inbaby diapers), and starches. Because these types of physical absorptiondesiccants are both inert and non-water soluble, they are preferred formany applications. In one embodiment, the molecular sieve pore sizesthat are suitable for use in the present invention include between about3 to 15 Angstroms; about 3 to 5 Angstroms, about 5 to 8:3 Angstroms; 4Angstroms; 5 Angstroms; 8 Angstroms and 10 Angstroms. In anotherembodiment, the pore size of silica gel is about 24 Angstroms. Amongother reasons, these innocuous characteristics are particularlycompatible with food products and medicinal products that may beenclosed within containers formed from the desiccant entrained polymers,or at least exposed thereto. As stated previously, however, any of thethree types may be employed within the polymers of the present inventionfor the purposes of producing a desiccant entrained polymer.

[0049] In another embodiment, component C may be composed of absorbingmaterials such as: (1) metals and alloys such as, but not limited to,nickel, copper, aluminum, silicon, solder, silver, gold; (2)metal-plated particulate such as silver-plated copper, silver-placednickel, silver-plated glass microspheres; (3) inorganics such as BaTiO₃,SrTiO₃, SiO₂, Al₂O₃, ZnO, TiO₂, MnO, CuO, Sb₂O₃, WC, fused silica, fumedsilica, amorphous fused silica, sol-gel silica, sol-gel titanates, mixedtitanates, ion exchange resins, lithium-containing ceramics, hollowglass microspheres; (4) carbon-based materials such as carbon, activatedcharcoal, carbon black, ketchem black, diamond powder; and (5)elastomers, such as polybutadiene, polysiloxane, and semi-metals,ceramic.

[0050] In another example, the absorbing material may be calcium oxide.In the presence of moisture and carbon dioxide, the calcium oxide isconverted to calcium carbonate. Accordingly, calcium oxide may be usedas the absorbing material in application where absorption of carbondioxide is needed. Such applications include preserving fresh foods(e.g. fruits and vegetables) that give off carbon dioxide.

[0051] It is believed that the higher the absorbing materialconcentration in the mixture, the greater the absorption capacity willbe of the final composition. However, the higher absorbing materialconcentration should cause the body to be more brittle and the mixtureto be more difficult to either thermally form, extrude or injectionmold. In one embodiment, the absorbing material loading level can rangefrom 10% to 20%, 20% to 40% and 40% to 60% by weight with respect to thepolymer.

[0052] In another embodiment, for example, the composition of thepresent invention may include a desiccant such as molecular sieves (i.e.component C), polypropylene (i.e. component A) and polyglycol (i.e.component B). The amounts of the various components would be forexample, from about 30-80 wt %, or from about 40-70 wt % of thedesiccant, or about 60 wt %; from about 20-40 wt % of the polypropylene,e.g. polypropylene homopolymer available from Exxon [3505], having amelt flow of 400, or about 30 wt %; and from about 5-20 wt % of thepolyglycol, e.g., poly[ethylene propylene glycol] available from Dow(15-200), or about 10 wt %.

[0053] In yet another embodiment, the particle (i.e. component C) may becomposed of a variety of releasing material. Such material may compriseany suitable form which will release dispersant to surroundingatmosphere, including solid, gel, liquid, and in some cases a gas. Thesesubstances can perform a variety of functions including: serving as afragrance, flavor, or perfume source; supplying a biologically activeingredient such as pesticide, pest repellent, antimicrobials, bait,aromatic medicines, etc.; providing humidifying or desiccatingsubstances; delivering air-borne active chemicals, such as corrosioninhibitors; ripening agents and odor-making agents, etc. For example,component C may be a particle having biocide properties. Such biocidesmay include, but are not limited to, pesticides, herbicides,nematacides, fungicides, rodenticides and/or mixtures thereof.

[0054] Other releasing materials include fragrances, including natural,essential oils and synthetic perfumes, and blends thereof. Typicalperfumery materials which may form part of, or possible the whole of,the active ingredient include: natural essential oils such as lemon oil,mandarin oil, clove leaf oil, petitgrain oil, cedar wood oil, patchoulioil, lavandin oil, neroli oil, ylang oil, rose absolute orjasminabsolute; natural resins such as labdanum resin or olibanum resin;single perfumery chemicals which may be isolated from natural sources ofmanufactured synthetically, as for example alcohols such as geraniol,nerol, citronellol, linalol, tetrahydrogeraniol, betaphenylethylalcohol, methyl phenyl carbinol, dimethyl benzyl carbinol, menthol orcedrol; acetates and other esters derived form such alcohols-aldehydessuch as citral, citronellal, hydroxycitronellal, lauric aldehyde,undecylenic aldehyde, cinnamaldehyde, amyl cinnamic aldehyde, vanillinor heliotropin; acetals derived from such aldehydes; ketones such asmethyl hexyl ketone, the ionones and methylionones; phenolic compoundssuch as eugenol and isoeugenol; synthetic musks such as musk xylene,musk ketone and ethylene brassylate.

[0055] In yet another embodiment, the particle (i.e. component C) may becomposed of various types of activation material. Generally, anactivation material includes a composition that requires a specificliquid, vapor, or gas to activate the composition and, after activation,the composition releases the desired vapor, liquid, or gas. In oneembodiment, moisture is used to activate the composition. In anotherembodiment, oxygen is used to activate the composition. In a furtherembodiment, an acid is used to activate the composition. In yet afurther embodiment, a base is used to activate the composition. In yetanother embodiment, a variety of materials may be released. Suchmaterial may comprise any suitable form which will release dispersant tosurrounding atmosphere, including solid, gel, liquid, and, in somecases, a gas. These substances can perform a variety of finctions,including: serving as a fragrance or perfume source; supplying abiologically active ingredient such as a biocide, antimicrobial agent,pesticide, pest repellent, bait, aromatic medicine, etc.; providinghumidifying or desiccating substances; or delivering air-borne activechemicals, such as corrosion inhibitors, ripening agents andodor-masking agents.

[0056] It is to be understood that two or more materials may be addedwith one functioning as an absorbing material and the other thenfunctioning as a releasing material to form an activation material. Anexample would be a desiccant (i.e. absorbing) and a releasing materialsuch as a dispersant.

[0057] Another example of activation materials are enzyme systems.Suitable enzyme systems may include glucose oxidase; a glucose/glucoseoxidase combination; a glucose oxidase/sucrose combination; astarch/amylase/glucose oxidase combination; acellulose/cellulase/glucose oxidase combination; a milkpowder/lactase/glucose oxidase combination; a glucose oxidase/glucoseisomerase/fructose combination; a glucose oxidase/lactase/wheysolids/lactose combination; a glucose oxidase/lactase/lactosecombination; a glucose oxidase/maltase/starch combination; a glucoseoxidase/maltase/maltose combination; a mushroom tyrosinase/tyrosinecombination; a glucose oxidase/sucrose/sucrase combination; analcohol/alcohol oxidase; a lactate/lactate oxidase; an amino acid/aminoacid oxidase; a golactose/golactose oxidase; a xanthine/xanthineoxidase; an amine/amine oxidase ; an ascorbate/ascorbate oxidase; achelione/chelione oxidase; and any combination of these enzymes.

[0058] In yet another embodiment of activation material, some catalyzedreactions may generate hydrogen peroxide as a byproduct. The releasedhydrogen peroxide may be of some benefit to extend shelf life of meats,poultry and fish if the hydrogen peroxide is in direct contact with thewet surfaces of those foods. Alternatively, concern about the generationof hydrogen peroxide may be minimized by including catalase in theenzyme system.

[0059] In a further embodiment, activation material may also be added toprovide the polymer with one or more specific properties, such asacidity, basicity, thermal conductivity, electrical conductivity,dimensional stability, low dielectric constant, high-dielectricconstant, ion-exchange capabilities, galvanic potential, flameretardency, etc.

[0060] It is believed that the higher the activation materialconcentration in the mixture, the greater the capacity will be of thefinal composition. However, the higher activation material concentrationshould cause the body to be more brittle and the mixture to be moredifficult to either thermally form, extrude or injection mold. In oneembodiment, the activation material loading level can range from 10% to20%, 20% to 40% and 40% to 60% by weight with respect to the polymer.

[0061] With respect to component A, in one embodiment, component A maybe a water-insoluble polymer such as a thermoplastic material. Examplesof suitable thermoplastic materials may include polyolefins such aspolypropylene and polyethylene, polyisoprene, polybutadiene, polybutene,polysiloxane, polycarbonates, polyamides, ethylene-vinyl acetatecopolymers, ethylene-methacrylate copolymer, poly(vinyl chloride),polystyrene, polyesters, polyanhydrides, polyacrylianitrile,polysulfones, polyacrylic ester, acrylic, polyurethane and polyacetal,or copolymers or mixtures thereof.

[0062] In an additional embodiment, component B may be a hydrophobicagent. For purposes of the present invention, the term “hydrophobicagent” is defined as a material that has a solubility in water of lessthan about 20% at 25\C. and atmospheric pressure. In one example,hydrophobic agents may be used in applications requiring the absorptionof non-polar gases. For example, a water-insoluble polymer (e.g.component A), a hydrophobic agent (e.g. component B) and an absorbingmaterial (e.g. component C) of the present invention may be used inapplication where removal of toxic gases and/or organic solvents arerequired such as in filter systems. It is understood that, in somecases, the use of a hydrophobic agent in combination with thewater-insoluble polymer and absorbing material may result in a two phasesystem.

[0063] In yet another embodiment, components A, B and C are first drymixed in a mixer such as a Henschel, and then fed to a compounder. ALeistritz twin screw extruder, for example, or a Werner Pfleider mixercan be used to achieve a good melt mix at about 140° C. to about 170° C.The melt can then be either extruded to form, for example, a film orconverted into pellets using dry air cooling on a vibrating conveyer.The formed pellets, containing channels, can, for example, then beeither injection molded into beads, sieves, or co-injected withpolypropylene as the inside layer of a container.

[0064] Moreover, in a further embodiment, it is believed that acomposition may be formed having channels composed of two discretepolymers (e.g. components B and B′) with each type of channel composedof a majority of either the same particles (e.g. component C) ordifferent particles (e.g. components C and C′) where B/B′ and C/C′ areselected, among other characteristics, based on their preferentialaffinities with each other. For example, a composition may be formed,wherein: (a) component A is a semicrystalline polymer; (b) component Band B′ are polymers; (c) components A, B and B′ are immiscible withineach other; (d) components C and C′ are particles; (e) the volumefraction of component A represents at least about 34% by volume of thetotal volume of components A, B, B′, C and C′; (f) the preferentialaffinity between components B and C is greater than either betweencomponents A and C and between components B′ and C; (g) the preferentialaffinity between components B′ and C′ is greater than either betweencomponents A and C′ and between components B and C′; (h) at least threephases are formed, one phase is composed of a majority of component A,the second phase is composed of a majority of component B and a majorityof component C, and the third phase is composed of a majority ofcomponents B′ and a majority of components C′; and (i) at least threephases form the co-continuous interconnecting channel morphology. It isfurther believed that such a composition could be designed to havemultiple characteristics. For example, a select channel morphology couldhave high moisture transmission properties with a majority of desiccantsresiding in these channels and another channel morphology within thesame composition could have high oxygen transmission properties withoxygen absorbing agents. In addition, as another example, additionalchannel morphology may also be designed using additional components(e.g. components B″, B′″, . . . and C″, C′″. . . ).

[0065] In yet a further embodiment, because the composition of thepresent invention may typically be more brittle than component A withoutcomponents B and C, the package may be molded so that an interiorportion of the package is the composition of the present invention whilethe exterior portions are formed from pure polymer or the composition ofthe present invention with a lower loading level components B and/or C.For example, a package having an interior portion composed of thecomposition of the present invention and an exterior portion composed ofpure polymer typically will not only be more durable and less brittle,but it will also act as a gas barrier that resists the transmission ofthe vapor from the exterior into the interior of the package. In thismanner, the absorption and/or releasing capacity of component C ispotentiated by exposing it exclusively to the interior of the packagefrom which it is desired that the vapor be withdrawn and retainedtherefrom.

[0066] The composition of the present invention has numerousapplications. The following examples are merely exemplary and are notmeant to limit the application of the present invention. One applicationis the construction of rigid containers that are suitable for containingrelatively small volumes of product such as food stuffs and medicines.In many cases, these types of products must be shipped and stored incontrolled environments (e.g. reduced moisture and/or oxygen). Inanother embodiment, the composition of the present invention may beformed into an insert for inclusion within the interior of thecontainer. An example of one form of an insert is a plug or sleeve ofany suitable shape. While the plug would serve its purpose by beingmerely deposited within the container, it may also be fixed to aninterior location so that it does move about within the interior space.In a f arther embodiment, it is anticipated that a plug formed into adisc may be shaped and sized to be pressed fit into the bottom of apolymer formed container.

[0067] In another embodiment, a liner may be formed from the compositionof the present invention that has an exterior surface substantiallyconforming to an interior surface of the container body. Like the disc,the liner may be sized so that it may be press-fit into position withinthe polymer body where it is held sufficiently snugly to prevent itsunintended disengagement therefrom. Alternatively, in a furtherembodiment, either the plug or liner may be initially constructed andallowed to harden, and then the container body subsequently constructedthereabout so that the greater shrinkage characteristics of the polymerbody not containing absorbing material tightly shrink-fits the containerbody about the plug or liner so that neither becomes easily disengagedfrom the other. In still a f uirther embodiment, the insert taking theform of either a plug or a liner may be substantially simultaneouslycomolded with the polymer container body so that each is integrallyjoined with the other. In the event of a co-molding process, theviscosities of the absorbing laden insert and the polymer container bodyshould typically be approximately equal to facilitate the proper anddesired location of the two phases of liquid or molten material that aremolded together.

[0068] In yet another embodiment, composition of the present inventionmay be used to form sheeting that is joined with another sheet. In atleast one embodiment, the sheets are effectively laminated one to theother so that an exterior layer may be established adjacent to thecomposition of the present invention which is substantially gasimpermeable. The laminate sheet may then be used to wrap an item whichis to be stored in a controlled environment. One means by which thejoinder process may be accomplished is through a thermal extrusionprocedure.

[0069] In each of the embodiments of the present invention describedherein, advantages and enhancements over the prior art methods andstructures stem from the discovery of the ability to create aco-continuous interconnecting channel morphology throughout thecomposition of the present invention so that a shaped article may beconstructed from the composition of the present invention. Furthermore,in one embodiment, the discovery of employing a hydrophilic agent thatalso acts as a transmission rate bridge between the exterior of thepolymer body and the interiorly located component C greatly enhances thestructures' ability to quickly remove a desired property locatedexteriorly to the composition or to quickly release a desired propertyto the exterior.

[0070] One embodiment of the present invention includes a process forproducing the composition of the present invention. In one embodiment,the process comprises blending a water-insoluble polymer (e.g. componentA) and a hydrophilic agent (e.g. component B). Either prior to blendingthe hydrophilic agent or after blending the hydrophilic agent, componentC is blended into the polymer so that the additive is uniformlydistributed within the polymer and the hydrophilic agent is distributedwithin the polymer. Subsequently, after the composition is solidified,the result is that the hydrophilic agent forms interconnecting channelsin the composition through which the desired property is transmittedthrough the polymer to component C within the composition. In anotherembodiment, component A, the hydrophilic agent (e.g. component B) andcomponent C are all thoroughly mixed in dry powder form, and then theblend is melted and formed into a desired shape by molding. Aco-continuous interconnecting channel morphology is formed in thecomposition.

[0071] Referring to FIG. 1 of the accompanying drawings of an embodimentof the present invention, an insert constructed from the composition ofthe present invention 20 is illustrated. For purposes of this disclosureof the present invention, the words “entrain” and “contain” have beenused interchangeably when referring to the inclusion of component C 30in composition 25. The insert is in the form of a plug 55 that may bedeposited into a container body 60 (FIG. 5) thereby establishing acontainer 61 (FIG. 5). Referring to FIG. 2, a cross-sectional view isshown of the plug 55 that has been constructed from a polymer mixturecomprising component A (25) that has been uniformly blended withcomponent C (30) and component B 35. In the illustration of FIG. 2, thecomposition of the present invention has been solidified so that theco-continuous interconnecting channel morphology 45 have formedthroughout the composition to establish passages throughout thesolidified plug 55. As may be appreciated in both FIGS. 1 and 2, thepassages terminate in channel openings 48 at an exterior surface of theplug 55.

[0072]FIG. 3 illustrates an embodiment of the present invention of aplug 55 which has been deposited into a container body 60 therebyestablishing a container 61 having the desired absorbing and/orreleasing and/or activation properties. The container body 60 has aninterior surface 65 and is constructed substantially from thecomposition of the present invention. In this manner, the transmissionproperty is resisted from being transmitted across a wall of thecontainer 60 when the container 60 is closed. As may be seen in FIG. 3,the plug 55 has been press fit into a bottom location of the container60. It is contemplated that the plug 55 may be merely deposited in thecontainer 60 for loose containment therein, but may also be coupled tothe body of the container 60 in a manner that fixes the plug 55 to thecontainer 60. The couple between the plug 55 and the container body 60is intended to prevent the dislocation and relative movement of the plug55 thereabout. This connection may be accomplished by a snug press fitbetween the plug 55 and the interior surface 65 of the body 60, or itmay be mechanically connected in such manners as adhesives, prongs, lipsor ridges that extend about the plug 55 to hold the plug 55 in place. Inyet another embodiment, it is contemplated that the container body 60may be molded about the plug 55 so that during the curing process of thecontainer body 60 the body 60 shrinks about the plug 55 thereby causinga shrink-fit to be established between the two components. This type ofcouplement may also be accomplished in a comolding process or sequentialmolding process with the same results achieved because the plug 55 willhave less shrinkage than the polymer 25 comprised container body 60.

[0073]FIG. 4 illustrates an absorbing container 61 having thecomposition of the present invention formed of a plug 55 located at abottom location of the container 60 similar to the configurationillustrated in FIG. 3, but the plug 55 and container body 60 arecomolded so that a unified body 61 is formed with a less distinctinterface between the plug 55 and body 60 components.

[0074]FIGS. 5 and 6 illustrate concepts similar to those of FIGS. 3 and4, however the proportions of the plug 55 have been extended so that aliner 70 is formed which covers a greater portion of the interiorsurface 65 of the desiccating container 61. The liner 70 is notlocalized in the bottom portion of the container body 60, but has wallswhich extend upwardly and cover portions of the walls of the container61. Like the plug 55, the liner 70 may be separately molded andsubsequently combined with the container body 60 or it may be comoldedtherewith into the unified body illustrated in FIG. 6.

[0075]FIGS. 7 and 8 illustrate an embodiment of the invention in which asheet of the present invention 75 is created for combination with abarrier sheet 80. The characteristics of the sheets are similar to thosedescribed with respect to the plug 55 and liner 70 and container body60. That is, FIG. 7 illustrates an embodiment in which the two sheets75, 80 are separately molded, and later combined to form a packagingwrap having the desired absorbing and/or releasing characteristics at aninterior surface and impermeability characteristics at an exteriorsurface. FIG. 8 illustrates a comolded process wherein an interfacebetween sheet 75 and the barrier sheet 80 is less distinct than in theembodiment of FIG. 7. This product can be produced by a thermal, formingprocess. It is contemplated that the separate sheets 75, 80 of FIG. 7may be joined together with an adhesive or other suitable means to forma laminate from the plurality of sheets 75, 80. Alternatively, thesheeting 75, 80 may be manufactured from a thermal extrusion processwhereby both sheets 75, 80 are manufactured at the same time andeffectively comolded together to form the embodiment illustrated in FIG.8.

[0076] In a further embodiment of the present invention, a plug 55 isformed from the mixture for inclusion within a container 60 that isconstructed from a barrier substance. In one embodiment, the plug 55 isdeposited into a container 60 that is constructed from a barriersubstance. In this manner, container 61 of the present invention iscreated. The plug 55 may be coupled to an interior surface of thecontainer body 60 so that the plug 55 is fixed relative to the container60.

[0077] Alternatively, a container 60 constructed from a barriersubstance may be molded about the plug 55 so that at least a portion ofthe plug 55 is exposed to an interior of the container 60. Plug 55 madeaccording to the present invention may also be co-molded with acontainer 60 that is constructed from a barrier substance so that atleast a portion of the plug 55 is exposed to an interior of thecontainer 60.

[0078] In another embodiment, a liner 70 may be formed from the mixture40 and then be included within a container 60 constructed from a barriersubstance. The liner 70 typically, but not necessarily, has an exteriorsurface configured for mating engagement with an interior surface 65 ofthe container 60. The liner 70 may be pressed into mating engagementwith the container 60 so that a container 61 is created wherein at leasta majority of the interior surface 65 of the container is covered by theliner 70. The liner 70 may be formed from the mixture 40 and then acontainer 60 constructed from a barrier substance may be molded aboutthe liner 70 so that at least a portion of the liner 70 is exposed to aninterior of the container 60 and a majority of an interior surface 65 ofthe container 60 is covered by the liner 70.

[0079] Alternatively, the liner 70 and container body 60 may be comoldedtogether into a unified body. The absorbing sheet 75 is combined with abarrier sheet 80 that is constructed of a barrier substance for use as apackaging wrap. The sheets 75, 80 may be laminated by thermal extrusion.

[0080] In still another embodiment of the present invention, a methodfor making a container 61 of the present invention is provided. Themethod includes forming a container 60 from substantially gasimpermeable material so that a gas barrier is created between aninterior and exterior of the container. An insert is formed fromcomposition of the present invention. The insert has an exterior surfacethat is configured for mating engagement with at least a portion of aninterior surface 65 of the container 60. The insert is installed intothe interior of the container 60 so that at least a portion of theexterior surface of the insert abuttingly engages the interior surface65 of the container 60. The engagement fixes the insert relative to thecontainer 60 and resists disengagement of the insert from the container60. The insert is exposed to the interior of the container 60 forabsorbing the desired property. The insert is pressed into the interiorof the container 60 with sufficient force that the insert fits tightlywithin the container 60 thereby resisting disengagement therefrom. Theinsert is sized and shaped so that the insert fits snugly into areceiving location within the interior of the container for retention atthe receiving location.

[0081] In yet another embodiment, a method for making an absorbingcontainer 61 is provided. A container is formed from substantially airand moisture impermeable material so that a barrier is establishedbetween an interior and exterior of the container 60. A substantiallysolid tablet or plug 55 is formed from the composition of the presentinvention 20, the tablet 55 being suitably sized to fit within theinterior of the container 60. The tablet 55 is then deposited into theinterior of the container 60 thereby establishing a means for absorbingthe desired material from the interior of the container 60 when thecontainer 60 is closed about the tablet 55.

[0082] The present invention will be illustrated in greater detail bythe following specific examples. It is understood that these examplesare given by way of illustration and are not meant to limit thedisclosure or claims. For example, although the following examples weretested at 10% Rh and 20% Rh at 72° F., the composition of the presentinvention is also suited for other conditions. Moreover, these examplesare meant to further demonstrate that the present invention has aco-continuous interconnecting channel morphology and that component Bpredominately resides in the interconnecting channels. All percentagesin the examples or elsewhere in the specification are by weight unlessotherwise specified.

EXAMPLE 1

[0083] The purpose of the following example is to demonstrate that thecomposition of the present invention has the co-continuousinterconnecting channel morphology by subjecting the following materialsto a swelling and weight loss analysis.

A. Preparation of Samples

[0084] Film #1: A blend of about 93% (w/w) of polypropylene (ExxonChemicals, tradename Escorene® polypropylene 3505G) and about 7% (w/w)of poly(ethylene glycol) (Dow Chemical, tradename E-4500) wassufficiently mixed to produce a uniform blend. The blend was then fedthrough a Leistritz twin screw extruder at temperatures in the sixteenzones ranging from about 145° C. to about 165° C., at a feed rate ofabout 40 lbs/hr, at a screw speed of about 460 rpm and a six inch die.The extruded composition was then fed through a three roll hot press attemperatures ranging from about 85° C. to about 92° C. to produce a filmof about 4 mil.

[0085] Film #2: A blend of about 68% (w/w) of polypropylene (ExxonChemicals, tradename Escorene® polypropylene 3505G) and about 3505G),about 12% (w/w) of poly(ethylene glycol) (Dow Chemical, tradenameE-4500) and about 20% (w/w) of a desiccant of molecular sieve (ElfAtochem, tradename Siliporite® molecular sieve, 4 Angstrom) wassufficiently mixed to produce a uniform blend. The blend was then fedthrough a Leistritz twin screw extruder at temperatures in the sixteenzones ranging from about 145° C. to about 165° C., at a feed rate ofabout 40 lbs/hr at a screw speed of about 460 rpm and a six inch die.The extruded composition was then fed through a three roll hot press attemperatures ranging from about 85° C. to about 92° C. to produce a filmof about 4 mil.

[0086] Film #3: A blend of about 34.88% (w/w) of polypropylene (ExxonChemical, tradename Escorene® polypropylene 3505G), about 11.96% (w/w)of poly(ethylene glycol) (Dow Chemical, tradename E-4500), about 52.82%(w/w) of a desiccant of molecular sieve (Elf Atochem, tradenameSiliporite® molecular sieve, 4 Angstrom) and about 0.34% (w/w) of a greycolorant was sufficiently mixed to produce a uniform blend. The blendwas then fed through a Leistritz twin screw extruder at temperatures inthe sixteen zones ranging from about 145° C. to about 165° C., at a feedrate of about 50 lbs/hr at a screw speed of about 460 rpm and a six inchdie. The extruded composition was then fed through a three roll hotpress at temperatures ranging from about 85° C. to about 92° C. toproduce a film of about 4 mil.

B. Swelling and Weight Loss Analysis

[0087] Circular disks (OD 1.1 cm) were cut from each of the threesamples. Initial dry weights of each sample was recorded. Samples weresubsequently incubated in 2.0 ml distilled water and left shaking atroom temperature. Periodically at 1, 2, 3, and 34 days, the disks wereremoved, the surface blotted dry and the sample weighed, to determinethe extent of swelling. At each timepoint, the distilled water wasreplaced to provide for sink conditions. At the end of the study, thesamples were lyophilized to remove the water and the sample weighed todetermine mass loss. FIG. 9 is a graph of the result of the analysis.Percent swelling is defined as the wet weight at a time point (t),divided by initial dry weight (zero) and multiplied by 100. ‘Dry’indicates the final lyophilized sample weight following the 34 dayincubation.

[0088]FIG. 9 shows film #1 did not swell or lose weight over the courseof 34 days. Thus, it is believed that this result shows that thepoly(ethylene glycol) (i.e., hydrophilic agent) was completely entrappedin the polypropylene (i.e., water-insoluble polymer). Film #2 gainedapproximately 3% of its initial weight by swelling and lostapproximately 9% of its initial weight at the end of the 34 days ofincubation. Film #3 gained approximately 6% of its initial weight andlost approximately 8% of its initial weight at the end of the 34 dayincubation period. These results demonstrate that interconnectingchannels from the exterior through the interior exist in the compositionof the present invention because water penetrated films #2 and #3 and asubstantial portion of the water soluble component (e.g., poly(ethyleneglycol)) of films #2 and #3 was extracted from the polymer.

EXAMPLE 2

[0089] The purpose of the following example is to demonstrate that thecomposition of the present invention has two separate phases consistingof a component A (e.g. water-insoluble polymer) and component B (e.g.hydrophilic agent).

A. Preparation of Samples

[0090] Film #4: 100% polypropylene (Exxon Chemicals, tradename Escorene®polypropylene 3505G) was fed through a Leistritz twin screw extruder attemperatures in the sixteen zones ranging from about 145° C. to about165° C., at a feed rate of about 40 lbs/hr, at a screw speed of about460 rpm and a six inch die. The extruded composition was then fedthrough a three roll hot press at temperatures ranging from about 85° C.to about 92° C. to produce a film of about 4 mil.

[0091] Film #5: A blend of about 88% (w/w) of polypropylene (ExxonChemicals tradename Escorene® polypropylene 3505G), about 12% (w/w) ofpoly(ethylene glycol) (Dow Chemical, tradename E-4500) was sufficientlymixed to produce a uniform blend. The blend was then fed through aLeistritz twin screw extruder at temperatures in the sixteen zonesranging from about 145° C. to about 165° C., at a feed rate of about 40lbs/hr, at a screw speed of about 460 rpm and a six inch die. Theextruded composition was then fed through a three roll hot press attemperatures ranging from about 85° C. to about 92° C. to produce a filmof about 4 mil.

[0092] Film #7: A blend of about 68% (w/w) of polypropylene (ExxonChemicals, tradename Escorene® polypropylene 3505G), about 12% (w/w) ofpoly(ethylene glycol) (Dow Chemical, tradename E-4500) and about 20%(w/w) of a desiccant of molecular sieve (Elf Atochem, tradenameSiliporite® molecular sieve, 4 Angstrom) was sufficiently mixed toproduce a uniform blend. The blend was then fed through a Leistritz twinscrew extruder at temperatures in the sixteen zones ranging from about145° C. to about 165° C., at a feed rate of about 12 lbs/hr, at a screwspeed of about 460 rpm and a six inch die. The extruded composition wasthen fed through a three roll hot press at temperatures of about 105° C.to produce a film of about 4 mil.

B. Thermal Analysis Using Differential Scanning Calorimetry (“DSC”)

[0093] The processed film samples were analyzed using a Perkin ElmerDSC7 equipped with a TAC 7DX thermal controller. Data were analyzedusing Perkin Elmer Pyris software (version 2.01). Samples were heatedfrom −50 to 250° C. at a rate of 10 or 15° C./min, then cooled at thesame rate and then heated once again to 250° C. at the same rate. Thefollowing table is the date collected from the DSC. The melting pointdata is given as the melting point peak (° C.) and enthalpy (H,joules/gm) for the first heating ramp (1°) and the second heating ramp(2°) . The column referring to FIGS. 10 through 18 is the graphicaloutput from the DSC that corresponds to the date from the table. Sincethe samples are only heated to 250° C., the molecular sieve in filmsamples #2, #3 and #7 was not melted and thus, no melting point date wasrecorded. Sample Figure # PEG Peak\C. PEG δH J/g PP Peak\C. PP δH J/g100% 1\63.808 190.362 none none poly(ethyleneglycol) Film #4 1\none none162.700 78.462 2\none none 157.200 96.123 Film #5 1\57.700  22.253161.700 80.524 2\58.033  20.361 157.366 79.721 Film #6 1\none none159.366 42.385 2\none none 160.033 42.876 Film #7 1\56.366  19.460162.200 70.073 2\57.200  17.094 156.866 58.038 Film #2 1\58.554  20.845163.062 60.577 [pre-incubation] 2\58.779  16.037 157.783 53.706 Film #21\55.804  0.379 163.062 86.215 [post-incubation] 2\57.529  0.464 158.53367.949 Film #3 1\59.308  18.849 162.562 40.291 [pre-incubation] 2\56.529 10.122 158.283 24.980 Film #3 1\55.554  0.138 160.562 46.931[post-incubation] 2\none none 156.033 26.081

[0094] The 100% poly(ethylene glycol) sample, exhibits a single meltingpoint at 63° C. while film #4 100% polypropylene has a melting point at157° C. Film #5 displayed both peaks at 58° C. (poly(ethylene glycol))and 157° C. (polypropylene), which indicates that the two polymers werephase separated. If the polymers were not phase separated but mixed,then the peaks would not be at the melt temperatures of the purepolymers, but shifted. Film #6 shows only the distinct polypropylenepeak at 160° C. The molecular sieves do not melt in this temperaturerange or affect the melting temperature of pure polypropylene. Film #7again shows two distinct peaks: one for poly(ethylene glycol) at 57° C.and one for polypropylene at 157° C. indicating that in the threecomponent mixture, all are phase separated.

[0095] Film samples #2 and 3 were part of the swelling and weight lossanalysis presented in Example 1. Once again two distinct peaks wereevident: one for poly(ethylene glycol) at 59° C. and one forpolypropylene at 158° C. indicating that in the three component mixture,all components were phase separated. However when the polymer film wasincubated in water for 34 days at room temperature (File #2:post-incubation) and tested by DSC, the positions of the peaks remainedthe same indicating the components were still phase-separated. Howeverthe area of the poly(ethylene glycol) peak (indicated by delta H,enthalpy) was greatly reduced. This result indicated that poly(ethyleneglycol) had been extracted by the prolonged water incubation. Also, theresult provided further confirmation for the weight loss data presentedin Example 1 and demonstrated that the poly(ethylene glycol) componentwas mostly extracted by means of interconnecting channels in the bulkpolypropylene matrix.

[0096] Film sample #3 showed the same effect as Film sample #2. Thepolypropylene delta H peak was not detectable (Film #3:post-incubation), demonstrating nearly complete extraction ofpoly(ethylene glycol) during water incubation. This confirmed the weightloss result of Example 1 in which the same film lost approximately 8% ofit's initial weight. The poly(ethylene glycol) composition of the samplewas approximately 12% (w/w).

[0097] In addition, the glass transition (T_(g)) analysis from the DSCdata of the samples of the present invention also demonstrate that thewater-insoluble polymer and the material exist in separate phases. Purepolypropylene exhibits a T_(g) of about −6 C. while pure poly(ethyleneglycol) exhibits a Tg at about −30 C. DSC data from film #5 exhibit twodistinct T_(g)'s, which correspond to the respective polymers (6 C. forpolypropylene and −30 C. for poly(ethylene glycol) and thus, indicates,further that the two components are phase separated.

EXAMPLE 3

[0098] The purpose of the following example is to demonstrate that thecomposition of the present invention has a co-continuous interconnectingchannel morphology and has component C (e.g. the water absorbingmaterial) intermixed within component B (e.g. hydrophilic agent).

A. Scanning Electron Microscopy (“SEM”) Method

[0099] The structural properties of the films was imaged using a HitachiS-2700 microscope operating at 8 kV accelerating voltage to minimizeirradiation damage. Each film sample was visualized in threeperspectives: 1) the film surface; 2) the fractured film cross-section(0°) and 3) the fractured film cross-section at a 90° angle with respectto orientation #2 (90°). Pre-incubation film samples were directlysputter coated with a 5-10 nm layer of gold-palladium with a PolaronInstruments Sputter Coater E5100. Post-incubation samples were incubatedat room temperature for 24 hrs in 10 ml of 70% ethanol (w/v) withagitation. The ethanol was discarded and the samples were air-driedovernight. Samples were then frozen and lyophilized overnight to removeany residual moisture and then sputter coated.

B. Morphology of Film Samples

[0100]FIGS. 19a-c are scanning electron photomicrographs of film sample#4—100% polypropylene. FIGS. 19a-c illustrate that a water-insolublepolymer is typically a dense, homogenous morphology with substantiallyno porosity. The outer surface is shown in FIG. 19a FIG. 19a shows anouter surface that is dense and displaying substantially no porosity.The cross-sectional view is shown in FIG. 19b at a magnification of 200times. FIG. 19b shows plate-like domains of polymer that were revealedduring brittle facture of the film. Another cross-sectional view isshown in FIG. 19c at a magnification of 1000 times. FIG. 19C shows adense, fibrillar morphology.

[0101]FIGS. 20a-c are scanning electron photomicrographs of film samples#5—about 88% polypropylene and 12% poly(ethylene glycol). FIGS. 20a-cillustrate that a two phase system consisting essentially of awater-insoluble polymer and hydrophilic agent has a heterogeneousmorphology with dense fibrillar matrix interspersed with domains oflamellar structures, which is the poly(ethylene glycol). FIGS. 20a-cfurther show voids between lamellar fibrillar and fibrillar structuresthat are channels and are oriented in the same direction. The outersurface is shown in FIG. 20a at a magnification of 1000 times. FIG. 20ashows an outer surface that is dense and displaying substantially noporosity. The cross-sectional view is shown in FIG. 20b at amagnification of 2,500 times. FIG. 20b shows fibrillar domains ofpolymer coated with lamellar strands of poly(ethylene glycol). FIG. 20cis a cross-sectional view of film sample #5 fractured a perpendicularangle and at a magnification of 1,500 times. FIG. 20c shows thefibrillar polypropylene matrix interspersed with solid, amorphouscylinder of poly(ethylene glycol).

[0102]FIGS. 21a-c are scanning electron photomicrographs of film sample#6—about 50% polypropylene and 50% molecular sieve. FIGS. 21a-cillustrate a typically homogeneous dense matrix and discrete molecularsieves can only occasionally be seen and are deeply embedded in thepolymer despite the high loading of molecular sieves. FIG. 21a shows theouter surface at a magnification of 1,000 times that is covered withlong channels measuring 5-30 microns. The outline of the molecularsieves (1-10 microns) can be seen embedded beneath the surface of thepolymer. The cross-sectional view is shown in FIG. 21b at amagnification of 200 times. FIG. 21b shows plate-like domains of polymerand a grainy appearance due to the high loading of molecular sieves.FIG. 21c is a cross-sectional view at a magnification 1,500 times andshows a dense morphology, substantially no porosity and many smallparticles embedded in the polymer.

[0103]FIGS. 22a-d are scanning electron photomicrographs of film samples#3—about 52% molecular sieve, about 34% polypropylene and about 12%poly(ethylene glycol). FIGS. 22a-d show a three phase system with ahighly porous morphology. FIG. 22a shows the outer surface at amagnification of 500 times that is covered with long channels, measuring5-30 microns, and that is filled with numerous discrete molecular sieveparticles. A cross-sectional view is shown in FIG. 22b at amagnification of 350 times. FIG. 22b shows a very porous morphology withlong channels running in the fracture orientation. FIG. 22c is across-sectional view in the perpendicular orientation at a magnificationof 350 times and appears to show holes. FIG. 22 is at highermagnifications—1,500 times. FIG. 22d shows channels containing discretemolecular sieves as well as agglomerates of many sieves embedded in thepoly(ethylene glycol). Consequently, based on FIG. 22b, it is believedthat the holes seen in FIGS. 22b and 22 c are locations where themolecular sieve fell out during fracture preparation for SEM.

[0104] In conclusion, Examples 1, 2 and 3 further confirm the theory forthe formation of a co-continuous interconnecting channel morphology.

EXAMPLE 4

[0105] The purpose of the following example is to demonstrate the waterabsorption properties of the compositions of the present invention.Samples of film with similar processing conditions as film #1 werehaving about 50% (w/w) of molecular sieve [4 Angstrom], about 12% (w/w)poly(ethylene glycol) and about 38% (w/w) polypropylene and wereevaluated for moisture adsorption of its total weight by using thefollowing test method (a) one environmental chamber was preset for 72 F.and 10% relative humidity (“Rh”) and another chamber was preset for 72F. and 20% Rh; (b) the dish was weighed and the weight recorded; (c) thescale was then tared to remove the weight of the dish from the balance;(d) the film was then added to the weighed dish; (e) the material wasthen weighed and the weight recorded; (f) the weigh dish with the samplewas placed in the environmental chamber; (g) the sample was left in thechamber for the desired time; (h) after the desired time was reached,the dish with the sample was removed, re-weighed and the weightrecorded; and (i) the precent moisture gained per gram of molecularsieve was calculated by (total weight gain of sample)/(weight ofmolecular sieve in sample)×100. The results are presented in FIGS. 23a[10% RH] and 23 b [20% Rh] The maximum theorectical precent moisturegained per weight of a 4 Angstrom molecular sieve is about 24 to 25%.FIGS. 23a and 23 b demonstrate that the high transmission rate (e.g.,moisture absorption rate) of the present invention.

[0106] Monolithic compositions having co-continuous interconnectingchannel morphology and their constituent compounds have been describedherein. As previously stated, detailed embodiments of the presentinvention are disclosed herein; however, it is to be understood that thedisclosed embodiments are merely exemplary of the invention that may beembodied in various forms. It will be appreciated that manymodifications and other variations that will be appreciated by thoseskilled in the art are within the intended scope of this invention asclaimed below without departing from the teachings, spirit and intendedscope of the invention.

What is claimed is:
 1. A composition having a co-continuousinterconnecting channel morphology comprising at least three components,(a) wherein component A is selected from the group of polymers that aresemicrystalline polymers and amorphous polymers, wherein the amorphouspolymers have a shear modulus greater than about 8 MPa; (b) whereincomponent B is a polymer; (c) wherein components A and B are immisciblewithin each other and, if components A and B react after mixing,components A and B are immiscible prior to reaction; (d) whereincomponent C is a particle; (e) wherein the volume fraction of componentA represents at least about 50% by volume of the total volume ofcomponents A, B and C; (f) wherein the preferential affinity betweencomponent B and component C is greater than between component A andcomponent C; (g) wherein at least two phases are formed, one phase iscomposed of a majority of component A, and the second phase is composedof a majority of component B and a majority of component C; and (h)wherein the two phases form the co-continuous interconnecting channelmorphology.
 2. A composition having a co-continuous interconnectingchannel morphology comprising at least three components, (a) whereincomponent A is selected from the group of thermoplastics that aresemicrystalline polymers and amorphous, wherein the amorphous polymershave a shear modulus greater than about 8 MPA; (b) wherein component Bis a polymer; (c) wherein components A and B are immiscible within eachother and, if components A and B react after mixing, components A and Bare immiscible prior to reaction; (d) wherein component C is a particle;(e) wherein the volume fraction of component A represents at least about50% by volume of the total volume of components A, B and C; (f) whereinthe preferential affinity between component B and component C is greaterthan between component A and component C; (g) wherein at least twophases are formed, one phase is composed of a majority of component A,and the second phase is composed of a majority of component B and amajority of component C; and (h) wherein the two phases form theco-continuous interconnecting channel morphology.
 3. A compositionhaving a co-continuous interconnecting channel morphology comprising atleast three components, (a) wherein component A is selected from thegroup of thermosets that are semicrystalline polymers and amorphouspolymers, wherein the amorphous polymers, have a shear modulus greaterthan about 8 Ma; (b) wherein component B is a polymer; (c) whereincomponents A and B are immiscible within each other and, if components Aand B react after mixing, components A and B are immiscible prior toreaction; (d) wherein component C is a particle; (e) wherein the volumefraction of component A represents at least about 50% by volume of thetotal volume of components A, B and C; (f) wherein the preferentialaffinity between component B and component C is greater than betweencomponent A and component C; (g) wherein at least two phases are formed,one phase is composed of a majority of component A, and the second phaseis composed of a majority of component B and a majority of component C;and (h) wherein the two phases form the co-continuous interconnectingchannel morphology.
 4. A composition having a co-continuousinterconnecting channel morphology comprising at least three components,(a) wherein component A is selected from the group of thermoplasticsthat are semicrystalline polymers and amorphous, wherein the amorphouspolymers have a shear modulus greater than about 8 MPA; (b) whereincomponent B is a polymer; (c) wherein components A and B are immisciblewithin each other and, if components A and B react after mixing,components A and B are immiscible prior to reaction; (d) whereincomponent C is a particle; (e) wherein the volume fraction of componentA represents at least about 50% by volume of the total volume ofcomponents A, B and C; (f) wherein the preferential affinity betweencomponent B and component C is greater than between component A andcomponent C; (g) wherein at least two phases are formed, one phase iscomposed of a majority of component A, and the second phase is composedof a majority of component B and a majority of component C; and (h)wherein the two phases form the co-continuous interconnecting channelmorphology.
 5. A composition having a co-continuous interconnectingchannel morphology comprising at least three components, (a) whereincomponent A is selected from the group of thermosets that aresemicrystalline polymers and amorphous polymers, wherein the amorphouspolymers, have a shear modulus greater than about 8 Ma; (b) whereincomponent B is a polymer; (c) wherein components A and B are immisciblewithin each other and, if components A and B react after mixing,components A and B are immiscible prior to reaction; (d) whereincomponent C is a particle; (e) wherein the volume fraction of componentA represents at least about 50% by volume of the total volume ofcomponents A, B and C; (f) wherein the preferential affinity betweencomponent B and component C is greater than between component A andcomponent C; (g) wherein at least two phases are formed, one phase iscomposed of a majority of component A, and the second phase is composedof a majority of component B and a majority of component C; and (h)wherein the two phases form the co-continuous interconnecting channelmorphology.
 6. The composition of claim 1, wherein component A isselected from the group consisting of polyolefins, polycarbonates andpolyamides.
 7. The composition of claim 1, wherein component B isselected from the group consisting of polyglycols, poly(ethylene vinylalcohols), and polyvinyl alcohol.
 8. The composition of claim 1, whereinthe composition is in the form, of a shaped article and the shapedarticle is selected from the group consisting of sheets, films, pelletsand beads.
 9. The composition of claim 1, wherein component A isselected from the group consisting of polyolefins, polycarbonates andpolyamides, and component B is selected from the group consisting ofpolyglycols.
 10. A composition having co-continuous interconnectingchannel morphology comprising at least five components, (a) whereincomponent A is selected from the group of polymers that aresemicrystalline polymers and amorphous polymers, wherein the amorphouspolymers have a shear modulus greater than about 8 MPa; (b) component Band B′ are polymers; (c) components A, B and B′ are immiscible withineach other; (d) components C and C′ are particles; (e) the volumefraction of component A represents at least about 34% by volume of thetotal volume of components A, B, B′, C and C′; (f) the preferentialaffinity between components B and C is greater than either betweencomponents A and C and between components B′ and C; (g) the preferentialaffinity between components B′ and C′ is greater than either betweencomponents A and C′ and between components B and C′; (h) at least threephases are formed, one phase is composed of a majority of component A,the second phase is composed of a majority of component B and a majorityof component C, and the third phase is composed of a majority ofcomponents B′ and a majority of components C′; and (i) at least threephases form the co-continuous interconnecting channel morphology.